Cylindrical air handler and cylindrical refrigerant coil

ABSTRACT

A refrigerant coil comprises a first pipe, a second pipe substantially parallel to the first pipe, and a plurality of coil segment pipes substantially parallel to each other. Each coil segment pipe has a first end connected to and in fluid communication with the first pipe and a second end connected to and in fluid communication with the second pipe. Each coil segment pipe forms a spiral with the first end being an outer end of the spiral and the second end being an inner end of the spiral such that the second pipe extends through a center of each of the coil segment pipe.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to pending U.S. Provisional Application Ser. No. 62/790,270, filed Jan. 9, 2019, the contents of which are incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

This invention relates to air conditioning systems, and more specifically for air handlers for air conditioning systems.

BACKGROUND

Heating, ventilation, and air conditioning (HVAC) systems heat and/or cool air within a house or other enclosed space by drawing air through return ducts into an air handler where the air is heated or cooled and then forced back into the space through supply ducts. The air handler typically includes a refrigerant coil through which a refrigerant is pumped. Air flowing across the refrigerant coil cools the air. The air handler also typically includes one or more heating elements, which may be one or more resistive wire coils in an electric system or one or more burners in a gas or oil system. Air flowing across the heating elements heats the air.

Air handlers typically have a square or rectangular cross-sectional shape. Such a shape causes turbulence in the air flowing through the air handler, which reduces the efficiency of the system.

BRIEF SUMMARY OF THE DISCLOSURE

A refrigerant coil comprises a first pipe, a second pipe substantially parallel to the first pipe, and a plurality of coil segment pipes substantially parallel to each other. Each coil segment pipe has a first end connected to and in fluid communication with the first pipe and a second end connected to and in fluid communication with the second pipe. Each coil segment pipe forms a spiral with the first end being an outer end of the spiral and the second end being an inner end of the spiral such that the second pipe extends through a center of each of the coil segment pipe.

The first pipe may be a supply pipe and the second pipe may be a return pipe such that refrigerant is adapted to flow into the refrigerant coil via the first pipe, from the first pipe into each of the coil segment pipes, and from each of the coil segment pipes into the return pipe from which the refrigerant exits the refrigerant coil.

The refrigerant coil may further comprise a plurality of thermal sink structures affixed to or integral with at least a portion of an outer surface of each of the coil segment pipes. The thermal sink structures may comprise fins or wires.

All of the coil segment pipes may be substantially a same size such that the refrigerant coil has an overall cylindrical shape.

In alternative embodiments of the invention, an air handler for a cooling system comprises a housing and a refrigerant coil positioned within the housing. The refrigerant coil comprises a first pipe, a second pipe substantially parallel to the first pipe, and a plurality of coil segment pipes substantially parallel to each other. Each coil segment pipe has a first end connected to and in fluid communication with the first pipe and a second end connected to and in fluid communication with the second pipe. Each coil segment pipe forms a spiral with the first end being an outer end of the spiral and the second end being an inner end of the spiral such that the second pipe extends through a center of each of the coil segment pipe.

The air handler may further comprise a fan positioned within or adjacent the housing to blow or draw air across the refrigerant coil.

The housing may be cylindrical. The air handler may be arranged such that a longitudinal axis of the housing is substantially horizontal. The air handler may further comprise a drain in a bottom surface of the housing. The air handler may further comprise dam structures positioned within the housing on opposing sides of the drain to contain condensate in a desired lower portion of the housing.

In alternative embodiments of the invention, a method of cooling air comprises activating a fan to draw air to be cooled into a first end of an air handler, across a refrigerant coil positioned within a housing of the air handler, and out a second end of the air handler. The refrigerant coil comprises a first pipe, a second pipe substantially parallel to the first pipe, and a plurality of coil segment pipes substantially parallel to each other. Each coil segment pipe has a first end connected to and in fluid communication with the first pipe and a second end connected to and in fluid communication with the second pipe. Each coil segment pipe forms a spiral with the first end being an outer end of the spiral and the second end being an inner end of the spiral such that the second pipe extends through a center of each of the coil segment pipe.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. The following detailed description of the disclosure will be better understood when read in conjunction with the appended drawings. It should be understood, however, that the disclosure is not limited to the precise arrangements and instrumentalities shown. In the drawings:

FIG. 1 is a top perspective view of a cylindrical air handler, in accordance with embodiments of the present invention.

FIG. 2 is a top perspective view of the cylindrical air handler of FIG. 1, with a portion of the housing removed.

FIG. 3 is a perspective view of a cylindrical refrigerant coil removed from the cylindrical air handler of FIG. 1 for visibility.

FIG. 4 is a bottom perspective view of the cylindrical air handler of FIG. 1.

FIG. 5 is a perspective view of a single coil segment of a cylindrical air handler showing additional detail.

DETAILED DESCRIPTION OF THE DISCLOSURE

Certain terminology is used in the following description for convenience only and is not limiting. The words “lower,” “bottom,” “upper,” and “top” designate directions in the drawings to which reference is made. The words “inwardly,” “outwardly,” “upwardly” and “downwardly” refer to directions toward and away from, respectively, the geometric center of the device, and designated parts thereof, in accordance with the present disclosure. Unless specifically set forth herein, the terms “a,” “an” and “the” are not limited to one element, but instead should be read as meaning “at least one.” The terminology includes the words noted above, derivatives thereof and words of similar import.

Embodiments of the invention are directed to a cylindrical air handler and a cylindrical refrigerant coil for use in a cylindrical air handler. Such a cylindrical air handler reduces turbulence of the air flowing through the air handler, and therefore has increased efficiency. The cylindrical refrigerant coil provides an effective mechanism for cooling the air in such a cylindrical air handler. Embodiments of the invention are also directed to a method of cooling air using a cylindrical air handler having a cylindrical refrigerant coil.

Referring now to the figures, a cylindrical air handler 10 comprises an outer housing 12 having a generally cylindrical shape. The housing 12 is typically constructed of sheet metal, but may be constructed of any suitable material. The housing 12 typically has a hinged or removable access panel or door 18 to enable the internal components to be accessed for servicing. The air handler 10 has a first open end 14 and a second open end 16. The supply duct(s) (not illustrated) may be connected to the air handler 10 via the first open end 14 and the return duct(s) (not illustrated) may be connected to the air handler 10 via the second open end 16 (or vice versa).

Air may be drawn into the cylindrical air handler 10 via a conventional “squirrel cage” fan 26 rotated by an electric motor 28. Any suitable type and size of fan and any suitable type and size of motor may be used. The fan and/or motor may be located within the housing 12 of the air handler 10, or outside of the housing 12 of the air handler 10 (e.g., in the ductwork). The air that is drawn into the cylindrical air handler 10 passes across the novel cylindrical refrigerant coil 20. (The refrigerant coil 20 may be termed a cylindrical coil as its overall shape is cylindrical. Alternatively, the refrigerant coil 20 may be termed a spiral coil as each segment of the coil comprises a segment of tubing bent into a spiral.)

As best seen in FIG. 3, the cylindrical refrigerant coil 20 comprises a plurality of coil segments 30 (fifteen coil segments 30 are illustrated, although fewer or more coil segments may be used depending on the desired cooling capacity). Each coil segment 30 has a spiral shape. Each spiral coil segment 30 is arranged parallel to the adjacent coil segment(s), such that the coil segments 30 form an overall cylindrical shape as illustrated. The coil segments 30 are typically constructed of copper tubing, and the copper tubing may have any suitable diameter depending on the desired cooling capacity of the system. The overall size of each spiral coil segment may vary depending on the desired cooling capacity and air handling capacity of the system. As illustrated in FIG. 5, most of the outer surface of each coil segment 30 would be covered by a large number of heat sink structures 42, such as cooling fins or cooling wires (such cooling fins and cooling wires are conventionally known to be used with refrigerant coils). The spacing of the spiral coil (i.e., how “tight” each spiral is) is selected to provide enough space for the heat sink structures and to enable proper air flow across the spiral coil segments. Similarly, the spacing between the coil segments is selected to provide enough space for the heat sink structures.

The outer end of each coil segment 30 is affixed to and in fluid communication with a refrigerant supply junction 32, while the inner end of each coil segment 30 is affixed to and in fluid communication with a refrigerant return junction 34. Refrigerant is pumped (via a pump, not illustrated) from a compressor (not illustrated) via a supply line 24 (a small portion of which is illustrated) into the supply junction 32. The refrigerant then flows from the supply junction 32 into each of the coil segments 30. The refrigerant then flows from the coil segments 30 into the return junction 34 and then back to the compressor via a return line 22 (a small portion of which is illustrated). (Alternatively, the refrigerant could be supplied to the coil segments via junction 34 and returned to the compressor via junction 32.) In this regard, the coil segments 30 are cooled via refrigerant circulating therethrough, such that the air flowing through the air handler 10 is cooled by flowing over the cooled coil segments.

The air handler 10 may also comprise a heating element 38, which comprises three resistive wire coils in the illustrated embodiment (fewer or more resistive wire coils may be used, or a different type of heating element may be used). Such a use of heating elements within an air handler is conventionally known.

When air is cooled by flowing over refrigerant coils, moisture in the air condenses and must be drained away. Conventional air handlers typically have a drain pan underneath to catch dripping condensation, and a drain tube to carry the condensation from the drain pan to the exterior of the conditioned space or to a plumbing drain. Such conventional drain pans are typically formed from sheet metal as shallow pans. These conventional drain pans are prone to damaging leaks, especially at the corner seams. Because of the cylindrical shape of the housing 12 which can be readily formed such that there are no seams on the lower portion, the housing 12 itself forms an effective drain pan (when the air handler is installed horizontally) that is much less likely to leak than conventional drain pans. It would typically be necessary to mount condensate barriers or dams 44 on opposing ends of the lower portion of the housing 12 (only one is visible in FIG. 2) to prevent the condensate from flowing out of the housing and into the supply and/or return ducts. Alternatively, a semi-cylindrical drain pan can be formed and placed within the housing 12 (instead of the housing itself functioning as the drain pan). In either case, a drain tube 40 (a small portion of which is illustrated) would be installed to drain the condensate from the drain pan.

One exemplary embodiment of the invention has the following dimensions/details: the refrigerant coil 20 is about 15 inches long and has an overall diameter of about 14 inches; the air handler 10 is about 48 inches long as has an overall diameter of about 18 inches; the pipe comprising each coil segment 30 has a ⅜ inch diameter and is about 10 feet long; there are twelve coil segments 30; the cooling wires 42 are about ½ inch long; the coil segments 30 are about 1 inch apart from each other; refrigerant supply junction 32 has a ⅜ inch diameter; and refrigerant return junction 34 has a ¾ inch diameter.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. 

That which is claimed:
 1. A refrigerant coil comprising: a first pipe; a second pipe substantially parallel to the first pipe; and a plurality of coil segment pipes substantially parallel to each other, each coil segment pipe having a first end connected to and in fluid communication with the first pipe and a second end connected to and in fluid communication with the second pipe, each coil segment pipe forming a spiral with the first end being an outer end of the spiral and the second end being an inner end of the spiral such that the second pipe extends through a center of each of the coil segment pipe.
 2. The refrigerant coil of claim 1, wherein the first pipe is a supply pipe and the second pipe is a return pipe such that refrigerant is adapted to flow into the refrigerant coil via the first pipe, from the first pipe into each of the coil segment pipes, and from each of the coil segment pipes into the return pipe from which the refrigerant exits the refrigerant coil.
 3. The refrigerant coil of claim 1, further comprising a plurality of thermal sink structures affixed to or integral with at least a portion of an outer surface of each of the coil segment pipes.
 4. The refrigerant coil of claim 3, wherein the thermal sink structures comprise fins or wires.
 5. The refrigerant coil of claim 1, wherein all of the coil segment pipes are substantially a same size such that the refrigerant coil has an overall cylindrical shape.
 6. An air handler for a cooling system, the air handler comprising: (a) a housing; and (b) a refrigerant coil positioned within the housing, the refrigerant coil comprising: (i) a first pipe; (ii) a second pipe substantially parallel to the first pipe; and (iii) a plurality of coil segment pipes substantially parallel to each other, each coil segment pipe having a first end connected to and in fluid communication with the first pipe and a second end connected to and in fluid communication with the second pipe, each coil segment pipe forming a spiral with the first end being an outer end of the spiral and the second end being an inner end of the spiral such that the second pipe extends through a center of each of the coil segment pipe.
 7. The air handler of claim 6, further comprising a fan positioned within or adjacent the housing to blow or draw air across the refrigerant coil.
 8. The air handler of claim 6, wherein the housing is cylindrical.
 9. The air handler of claim 8, wherein the air handler is arranged such that a longitudinal axis of the housing is substantially horizontal.
 10. The air handler of claim 9, further comprising a drain in a bottom surface of the housing.
 11. The air handler of claim 10, further comprising dam structures positioned within the housing on opposing sides of the drain to contain condensate in a desired lower portion of the housing.
 12. The air handler of claim 6, wherein the first pipe is a supply pipe and the second pipe is a return pipe such that refrigerant flows into the refrigerant coil via the first pipe, from the first pipe into each of the coil segment pipes, and from each of the coil segment pipes into the return pipe from which the refrigerant exits the refrigerant coil.
 13. The air handler of claim 6, wherein the refrigerant coil further comprises a plurality of thermal sink structures affixed to or integral with at least a portion of an outer surface of each of the coil segment pipes.
 14. The air handler of claim 13, wherein the thermal sink structures comprise fins or wires.
 15. The air handler of claim 6, wherein all of the coil segment pipes are substantially a same size such that the refrigerant coil has an overall cylindrical shape.
 16. A method of cooling air, the method comprising: activating a fan to draw air to be cooled into a first end of an air handler, across a refrigerant coil positioned within a housing of the air handler, and out a second end of the air handler; wherein the refrigerant coil comprises: a first pipe; a second pipe substantially parallel to the first pipe; and a plurality of coil segment pipes substantially parallel to each other, each coil segment pipe having a first end connected to and in fluid communication with the first pipe and a second end connected to and in fluid communication with the second pipe, each coil segment pipe forming a spiral with the first end being an outer end of the spiral and the second end being an inner end of the spiral such that the second pipe extends through a center of each of the coil segment pipe.
 17. The method of claim 16, wherein the housing is cylindrical.
 18. The method of claim 17, wherein the air handler is arranged such that a longitudinal axis of the housing is substantially horizontal.
 19. The method of claim 18, further comprising a drain in a bottom surface of the housing.
 20. The method of claim 19, further comprising dam structures positioned within the housing on opposing sides of the drain to contain condensate in a desired lower portion of the housing.
 21. The method of claim 16, wherein the first pipe is a supply pipe and the second pipe is a return pipe such that refrigerant flows into the refrigerant coil via the first pipe, from the first pipe into each of the coil segment pipes, and from each of the coil segment pipes into the return pipe from which the refrigerant exits the refrigerant coil.
 22. The method of claim 16, wherein the refrigerant coil further comprises a plurality of thermal sink structures affixed to or integral with at least a portion of an outer surface of each of the coil segment pipes.
 23. The method of claim 22, wherein the thermal sink structures comprise fins or wires.
 24. The method of claim 16, wherein all of the coil segment pipes are substantially a same size such that the refrigerant coil has an overall cylindrical shape. 